Movincool CLASSIC PLUS 26 Service Manual
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Movincool CLASSIC PLUS 26 Service Manual

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M A N U A L
S E R V I C E
CLA SSI C PLUS 26
DENSO SALES CALIFORNIA, INC.
REGISTERED TO ISO 9002
FILE NO. A55537

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Summary of Contents for Movincool CLASSIC PLUS 26

  • Page 1 M A N U A L S E R V I C E CLA SSI C PLUS 26 DENSO SALES CALIFORNIA, INC. REGISTERED TO ISO 9002 FILE NO. A55537...
  • Page 2 All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to make changes without prior notice. MovinCool is a registerd trademark of DENSO Sales California, Inc.
  • Page 3 S E R V I C E M A N U A L CLA SSI C PLUS 26...

  • Page 5: Definition Of Terms

    FOREWORD DEFINITION OF TERMS WARNING: Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation. CAUTION: Describes precautions that should be observed in order to prevent damage to the unit or its components, which may occur during installation or unit operation if sufficient care is not taken.

  • Page 7: Table Of Contents

    Table of Contents FOREWORD ..........................i DEFINITION OF TERMS ......................i GENERAL PRECAUTIONS ......................i GENERAL DESCRIPTION ......................1 CONSTRUCTION, SPECIFICATIONS & DATA ................ 3 REFRIGERANT SYSTEM ......................9 ELECTRICAL SYSTEM ......................14 TROUBLESHOOTING AND REPAIR ..................19...

  • Page 9: General Description

    GENERAL DESCRIPTION Generally speaking, conventional air conditioners cool the entire enclosed environment. They act as “heat exchangers”, requiring an interior unit (evaporator) to blow cool air into the interior and an exterior unit (condenser) to exhaust exchanged heat to the out- doors.
  • Page 10 GENERAL DESCRIPTION...

  • Page 11: Construction, Specifications & Data

    CONSTRUCTION, SPECIFICATIONS & DATA Construction of Classic Plus 26...
  • Page 12 CONSTRUCTION, SPECIFICATIONS & DATA Construction Diagram of Classic Plus 26...
  • Page 13 CONSTRUCTION, SPECIFICATIONS & DATA Basic Construction The MovinCool Spot Cooling System is compact in construction because the con- denser and the evaporator are enclosed in one unit. The interior is divided into three sections. The upper front face is equipped with the evaporator, while the lower front face contains the drain tank.
  • Page 14 CONSTRUCTION, SPECIFICATIONS & DATA Rating Conditions dry bulb F (35 wet bulb F (28.3 humidity (60%) Specifications power frequency 60Hz line voltage, single phase 208/230V power consumption 3.37/3.24 Kw current consumption 16.8/14.6 Amps power factor starting current power cord 12 (3-core) AWG Cooling Unit cooling capability 6,500 Kcal/hr...
  • Page 15 CONSTRUCTION, SPECIFICATIONS & DATA 10.60 2.62 3.84 7.28 29.24 23.76 12.56 2.80 3.72 21.88 16.80 28.40 19.60 Exterior Dimensions...
  • Page 16 CONSTRUCTION, SPECIFICATIONS & DATA Cool Air Temperature Difference Curve (high speed only) Cooling Capability Curve (high speed only) Power Consumption Curve (high speed only)

  • Page 17: Refrigerant System

    REFRIGERANT SYSTEM The component parts of the refrigerant system include the following: • Compressor • Evaporator • Condenser • High pressure switch • Capillary tube • Modulating tank These parts are all connected by copper piping. All the connections have been brazed. Modulating Tank Evaporator Condenser...
  • Page 18 REFRIGERANT SYSTEM 1. Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. A. Compressor Theory of Operation The scroll utilizes an involute spiral which, when matched with a mating scroll form, generates a series of crescent-shaped gas pockets between the two members.
  • Page 19 REFRIGERANT SYSTEM 4) By the time the gas arrives at the center port, discharge pressure has been reached. 5) Actually, during operation, all six gas passages are in various stages of com- pression at all times, resulting in nearly continuous suction and discharge. NOTE: Upon compressor shut-off, the compressor may run backward for a moment or two until internal pressures equalize.
  • Page 20 REFRIGERANT SYSTEM 3. Capillary Tube The capillary tube is a long thin tube and its line flow resistance serves as an expansion valve. The length and the inner diameter of the capillary tube are determined according to the capacity of refrigeration system, operating conditions and the amount of refrigerant.
  • Page 21 REFRIGERANT SYSTEM Condenser Inlet Pipe Evaporator Inlet Pipe Evaporator Compressor Outlet Pipe Discharge Pipe Compressor Outlet Pipe Capillary Tube Connecting Tube Connecting Tube (condenser to (condenser to capillary tube) capillary tube) Compressor Compressor Connecting Pipe Suction Pipe Suction Pipe (evaperator to (insulated) (insulated) compressor)

  • Page 22: Electrical System

    ELECTRICAL SYSTEM HPRS G T R IOLC J101 J102 J103 J104 J8 (AUX1) IOLF J201 Attachment Plug IOLC Internal Overload Protector of Compressor Terminal Block IOLF Internal Overload Protector of Fan Motor Control Board HPRS High Pressure Switch Relay Board Full Drain Warning Switch Fan Motor Freeze Protection Thermistor...
  • Page 23 ELECTRICAL SYSTEM 1. Basic Operation of Classic Plus 26 Electrical Circuit There are two basic components used to control the operation of the Classic Plus 26 Electrical System: • Control Panel Assembly • Control Box The Control Panel Assembly contains the Control Panel, Control Board (with inputs for the freeze and room temperature thermistors), drain switch, and a microprocessor.
  • Page 24 ELECTRICAL SYSTEM 2. Control Box A. Capacitors The capacitors are used to temporarily boost Relay Board the power output available to the fan motor Relay Board Fuse DIP Switch and the compressor at start-up. The specifications of each capacitor are listed below: Terminal Block CAPACITOR...
  • Page 25 ELECTRICAL SYSTEM 3. Fan Motor The fan motor is a single phase, induction type two-speed motor. The motor rotates fans on the evaporator side and the condenser side at the same time. Specifications: Rated Voltage: 230 volts 60 Hz Rated Output: 559 watts 355 watts CF1 (White) CF2 (Brown/White)
  • Page 26 ELECTRICAL SYSTEM 6. Condensate Pump Kit (optional) The Classic Plus 26 model comes standard with a drain tank, which collects the water that forms on the evaporator during normal cooling operation. If the unit is required to operate continuously without periodic emptying of this tank, a condensate pump may be needed.

  • Page 27: Troubleshooting And Repair

    TROUBLESHOOTING AND REPAIR Before troubleshooting the system, the following inspection should be performed. 1. Inspection of Power Source Voltage Check the voltage of the power source. Single phase 208/230 volts (60Hz) Check the operation and condition of the fuse or circuit breaker in the power source. 2.
  • Page 28 TROUBLESHOOTING AND REPAIR In case of trouble, perform the following inspection before disassembly. 5. Inspection of Spine Fins To inspect the spine fins of either the evaporator or condenser you must remove the air filters. After removal of the air filters, inspect the spine fins for any dirt, dust, lint, or debris that may have caused poor cooling performance of the unit.
  • Page 29 TROUBLESHOOTING AND REPAIR 8. Disassembly 1. Control panel 10. Front panel 2. Upper panel 11. Blower housing (evaporator) 3. Right side panel 12. Drain pan 4. Air filter 13. Left side panel 5. Blower housing (condenser) 14. Drain tank 6. Condenser fan 15.
  • Page 30 TROUBLESHOOTING AND REPAIR A. Remove Drain Tank. Removal of Drain Tank B. Remove (8) screws from the ducts, then remove the 2-ducts. Removal of Duct Screws and Ducts C. Remove (4) screws from the Service Panel. Removal of Service Panel Screws D.
  • Page 31 TROUBLESHOOTING AND REPAIR E. Remove remaining (13) screws and the back panel. Removal of Back Panel Screws Remove (14) screws from the Top Panel. Removal of Top Panel Screws G. Top Panel (4). Removal of Top Panel...

  • Page 32: Relay Board

    TROUBLESHOOTING AND REPAIR HPRS G T R IOLC J101 J102 J103 J104 J8 (AUX1) IOLF J201 Attachment Plug IOLC Internal Overload Protector of Compressor Terminal Block IOLF Internal Overload Protector of Fan Motor Control Board HPRS High Pressure Switch Relay Board Full Drain Warning Switch Fan Motor Freeze Protection Thermistor...
  • Page 33 TROUBLESHOOTING AND REPAIR ˚ ˚ Connections to Relay Board Connections to Control Board...
  • Page 34 TROUBLESHOOTING AND REPAIR 9. Removal of Electrical Parts 1. Condenser fan 5. Middle Frame 2. Blower housing (condenser) 6. Evaporator fan 3. Fan motor 7. Blower housing (evaporator) 4. Motor bracket 8. Air flow guide Disassembly of Blower...
  • Page 35 TROUBLESHOOTING AND REPAIR 10. Removal of Blower Assembly A. Loosen the set screw using an allen wrench and then remove the centrifugal fan. Removal of Centrifugal Fan B. Remove the two (2) nuts on the inside of the housing in the locations shown. A - NUT Removal of Blower Housing C.
  • Page 36 TROUBLESHOOTING AND REPAIR D. Remove the centrifugal fan by loosening the set screw on the shaft. Remove the fan motor, by loosening “A” nuts. Removal of Fan Motor E. Remove (7) screws from Left Side Panel. Removal of Left Side Panel Screws Remove (7) screws from Right Side Panel.
  • Page 37 TROUBLESHOOTING AND REPAIR G. Remove (2) screws from Control Panel Assembly Right Stay. Removal of Right Stay Screws H. Remove (2) screws from Control Panel Assembly Left Stay. Removal of Left Stay Screws Disconnect the following connectors from the control board: (1) Wire Harness, Relay Board to Control Board J201 (10-pin) (2) Drain Tank Switch J103 (2-pin)
  • Page 38 TROUBLESHOOTING AND REPAIR J. Remove the five (5) screws from the control board on the control panel assembly. Remove the control board. Removal of Control Board 11. Inspection of Capacitor (Fan Motor and Compressor) Ohmeter Method – Set the ohmeter to the 100K range.
  • Page 39 TROUBLESHOOTING AND REPAIR 13. Inspection of Drain Switch Check for continuity between terminals 1 and 2. TOP OF Continuity should exist. With switch depressed, BASE continuity should not exist between terminals 1 PLATE and 2. If continuity is not as specified above, replace the switch.
  • Page 40 TROUBLESHOOTING AND REPAIR 16. Inspection of High Pressure Switch Check for continuity across both terminals of the high pressure switch or the J104 connector. With pressure equalized when the unit is stopped, there should be continuity across both terminals and the J104 connector. If there is no continuity (open circuit), replace the high pressure switch.
  • Page 41 TROUBLESHOOTING AND REPAIR • BRAZED FITTING AND ITS CLEARANCE In general, the strength of brazing filler metal is lower than that of the base metal. So, the shape and clearance of the brazed fitting are quite important. As for the shape of the brazed fitting, it is necessary to maximize its adhesive area.
  • Page 42 TROUBLESHOOTING AND REPAIR B. Removal of Refrigeration Cycle Components CAUTION: 1. Before any refrigeration cycle component can be replaced, it is necessary to recover the refrigerant using standard recovery procedures and equipment. 2. To prevent oxidation, dry nitrogen should be conducted (flow rate 1 liter/min) through the pinch-off tube during any brazing operation.
  • Page 43 TROUBLESHOOTING AND REPAIR 21. Charging the System with R-22 Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R-22. WARNING: When handling refrigerant (R-22), the following precautions should always be observed: •...
  • Page 44 TROUBLESHOOTING AND REPAIR (3) Connect the charging hoses (red - high pressure side, blue - low pressure side) of the gauge manifold to the process tube fittings. NOTE: Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa.
  • Page 45 TROUBLESHOOTING AND REPAIR D. Checking Gas Leak (1) Remove the charging hose (green) from the vacuum pump, and connect the hose to the refrigerant cylinder (R22). (2) Loosen the nut on the gauge manifold side of the charging hose (green). Evacuating Air Inside Charging Hose (3) Open the high pressure valve of the gauge manifold.
  • Page 46 TROUBLESHOOTING AND REPAIR 22. Refrigerant Charging Work A. Refrigerant Charging (1) Remove the charging hose (green) from the vacuum pump, and connect it to the refrigerant cylinder (R-22). (2) Loosen the nut on the gauge manifold side of the charging hose (green). Open the valve of the charging hose (green).
  • Page 47 TROUBLESHOOTING AND REPAIR B. Removal of Gauge Manifold (1) Crimp the pinch-off tube with a pinch-off tool. (2) Remove the gauge manifold and the process tube fitting. Crush the end of the pinch-off tube. (3) Braze the end of the pinch-off tube. (4) Ensure that a gas leak is not present at the pinched off portion and the brazed end.
  • Page 48 TROUBLESHOOTING AND REPAIR 27. Schematic...
  • Page 49 DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT First Issue: May 1999 DSCA P/N: LA990009-0549 Printed in U.S.A.
  • Page 50 (800) 264-9573 www.movincool.com DSCA P/N: LA990009-0549...

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